107692-0040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076920040


107692-0040 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107692-0040 1076920040

Service parts 107692-0040 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-1000
3. GOVERNOR 105921-4650
4. SUPPLY PUMP 105237-4130
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-0820
7. COUPLING PLATE 156638-1920
9. _
10. NOZZLE AND HOLDER ASSY 105101-7230
11. Nozzle and Holder 16600-95016
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-4390
14. NOZZLE 105015-8870
15. NOZZLE SET

Include in #1:

107692-0040 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107692-0040 1076920040


Zexel num
Bosch num
Firm num
Name
107692-0040 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   134424-4120
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
PS/ACT control unit part no.   407910-3 03*
Selector switch no.   01
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   15
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   5.6 5.57 5.63
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.75 60.25
Difference between angles 2
Cyl.1-2
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cal 1-3
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-5
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   -
Rack position   14.8
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   115.4 113.4 117.4
Max. variation between cylinders %   0 -4 4
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.5+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   9.5 7.7 11.3
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(14.8)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   115.4 114.4 116.4
Basic   *
Fixing the lever   *
Boost pressure kPa   80 80
Boost pressure mmHg   600 600
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_04
Adjusting point   B
Rack position   R2(R1-2. 65)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   94.8 90.8 98.8
Fixing the lever   *
Boost pressure kPa   80 80
Boost pressure mmHg   600 600
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-1.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.1 49.1 57.1
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-2.45
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   92.9 88.9 96.9
Fixing the lever   *
Boost pressure kPa   80 80
Boost pressure mmHg   600 600
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-1.5
Boost pressure kPa   12 8 16
Boost pressure mmHg   90 60 120
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2-0.4
Boost pressure kPa   45.3 44 46.6
Boost pressure mmHg   340 330 350
Boost compensator adjustment_03
Pump speed r/min   500 500 500
Rack position   R2(R1-2. 65)
Boost pressure kPa   66.7 66.7 66.7
Boost pressure mmHg   500 500 500
0000001601
CU407980-224*   *
Actuator retarding type   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2.5 2.45 2.55
Output voltage V   2.83 2.82 2.84
Adjustment   *
_02
CU407980-224*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.6 5.57 5.63
Output voltage V   1.2 1 1.4
Confirmation   *
_03
CU407980-224*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *
_04
CU407910-303*   *
Actuator retarding type   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2.5 2.45 2.55
Output voltage V   2.83 2.82 2.84
Adjustment   *
_05
CU407910-303*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.6 5.57 5.63
Output voltage V   1.2 1 1.4
Confirmation   *
_06
CU407910-303*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 107692-0040
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F52 BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 107692-0040
F:Full speed I:Idle (1)Stopper bolt setting (2)-
----------

----------
a=25.5deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 107692-0040
N:Pump normal S:Stop the pump. (1)- (2)Set the stopper bolt so that speed = aa and rack position = bb. Confirm non-injection. Next, confirm non-injection at speed = cc.
----------
aa=1400r/min bb=5-0.5mm cc=300r/min
----------
a=20deg+-5deg b=37deg+-5deg

0000001301

Test data 107692-0040
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.6+-0.03mm
----------
a=(50deg)

0000001401

Test data 107692-0040
(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

Test data 107692-0040
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107692-0040
C:Shim
----------

----------

0000001901

Test data 107692-0040
A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 SPEED SENSOR

Test data 107692-0040
(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

0000002301 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=375r/min Ra=8.3+-0.1mm
----------

0000002401 RACK SENSOR

Test data 107692-0040
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1400r/min Ra=R1(14.8)mm
----------

0000002501 ACS

Test data 107692-0040
(A) Aneroid compensator (B) Set screw (C) Boost pressure inlet (D) Rack positioning screw (E): Aneroid compensator main body (F) Boost compensator spring (G): Aneroid compensator spring (H): Adjusting notch (I) Push rod 1. Instructions for adjusting the boost compensator with the aneroid compensator (1)Select a pushrod to obtain L1 at full boost. (2)Remove the aneroid compensator main body. (3)Adjust the booster compensator stroke by turning the screw at (D. (4)Adjust the beginning of boost compensator operation by turning the notch at (H). (5)Install the aneroid compensator at full boost state. (6)Turn (B)'s set screw so that the distance between the snapring and the body is L2. (7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
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Timing setting ACS

Test data 107692-0040
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1400r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(14.8)mm Rb=R1-0.5mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=58.7+-0.7kPa(440+-5mmHg) Q1=115.4+-1cm3/1000st Q2=(106.7)+-1.6cm3/1000st




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